Allen-Bradley 1395 Troubleshooting Manual

Brand: Allen-Bradley

Model: 1395

Type: Troubleshooting Manual

Troubleshooting Guide

1395 Digital DC

Drive

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Important User Information

Solid state equipment has operational characteristics differing from those of

electromechanical equipment. “Safety Guidelines for the Application,

Installation and Maintenance of Solid State Controls” (Publication SGI-1.1

available from your local Rockwell Automation Sales Ofﬁce or online at

http://www.ab.com/manuals/gi) describes some important differences

between solid state equipment and hard-wired electromechanical devices.

Because of this difference, and also because of the wide variety of uses for

solid state equipment, all persons responsible for applying this equipment

must satisfy themselves that each intended application of this equipment is

acceptable.

In no event will Rockwell Automation, Inc. be responsible or liable for

indirect or consequential damages resulting from the use or application of

this equipment.

The examples and diagrams in this manual are included solely for

illustrative purposes. Because of the many variables and requirements

associated with any particular installation, Rockwell Automation, Inc.

cannot assume responsibility or liability for actual use based on the

examples and diagrams.

No patent liability is assumed by Rockwell Automation, Inc. with respect to

use of information, circuits, equipment, or software described in this

manual.

Reproduction of the contents of this manual, in whole or in part, without

written permission of Rockwell Automation, Inc. is prohibited.

Throughout this manual we use notes to make you aware of safety

considerations.

Attentions help you:

• identify a hazard

• avoid the hazard

• recognize the consequences

Important: Identiﬁes information that is especially important for successful

application and understanding of the product.

ATTENTION: Identiﬁes information about practices or

circumstances that can lead to personal injury or death, property

damage, or economic loss.

Shock Hazard labels may be located on or inside the drive to

alert people that dangerous voltage may be present.

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Table of Contents

Chapter 1 Understanding the Basic Principles

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

Required Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

ESD Sensitivity Precaution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

Safety Facts to Read Before Proceeding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

Chapter 2 Malfunctions with Indications

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

Hard Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

Soft Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

Warning Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

Fault Response Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

Fault Setup Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4

Fault Status Indicators. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5

Bulletin 1300 Programming Terminal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7

Fault Descriptions and Recovery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7

Fault Display on HHT or DHT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7

System Processor Faults (SP–XX) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7

Velocity Processor (VP–XX) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12

Current Processor Faults (CP–XX) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22

Final Fault Recovery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-32

Chapter 3 Malfunctions Not Indicated by a Fault

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

Logic Control Malfunctions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

Link/Conﬁguration Parameter Malfunctions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

Velocity Control Malfunctions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

Velocity Feedback Device Malfunction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9

Encoder Device Malfunction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9

Analog Tachometer Malfunction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13

Armature Current Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15

Main Control Board Test Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16

Field Current Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19

Magnetics/Power Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22

Series A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22

Series B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-29

Auto Tuning Malfunctions (Series A & B) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-34

Chapter 4 Using Trending to Aid Troubleshooting

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

Trend Programming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

Examining Trend Data With a Program Terminal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3

Examining Trend Data with the Node Adapter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4

Examining Trend Data with the Discrete Adapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4

Examples of Trends. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4

System Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7

Ground Network Considerations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7

Electrical Noise Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8

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2 Table of Contents

Chapter 5 Manually Tuning the 1395 Drive

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

Tools & Test Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

Current Loop Tuning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

Velocity Loop Tuning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3

Field Flux Tuning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4

Chapter 6 Test Points

General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

Main Control Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

Power Stage Interface/Switcher Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3

Power Stage Interface Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4

Power Supply Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4

Appendix A Parameter List/Record

General Checklist. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1

Drive Nameplate Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1

Wiring and Control Board Checks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1

Measurement Record . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-2

Parameter Record. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-3

Index

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Chapter 1

Understanding the Basic Principles

General

This guide is intended to help you deﬁne troubleshooting techniques and

procedures and help simplify servicing of the Bulletin 1395 DC Drive by

identifying likely causes for malfunction. The 1395 employs extensive

diagnostics to aid in correcting many malfunctions that may occur in the

system. This guide is designed to help interpret the diagnostic response of

the Drive when a malfunction occurs. It will also aid in diagnosing

malfunctions that do not solicit a fault response from the Drive. Possible

corrective measures will be explained to help get the Drive repaired or

functional as quickly as possible for all types of malfunctions.

Required Equipment

In addition to a Bulletin 1300 Programming Terminal the following should

be available before initiating any troubleshooting procedures:

• Digital Multimeter (DMM) capable of 1000VDC/750VAC, with a one

megohm minimum input impedance.

• Assorted screwdrivers (Phillips and Straight).

• Clamp on Ammeter (AC/DC) with current ratings to 3X rated armature

current output of 1395.

• Dual trace oscilloscope with differential capability, digital storage, with

two X10 and one X100 calibrated probes. (Optional but recommended.)

• Hand Tachometer used to monitor motor velocities.

• Bulletin 1395 Installation Manuals for:

– Programming Terminal (Bulletin 1300)

– Adapter Boards

ATTENTION: Only personnel familiar with the 1395 Drive

System and the associated machinery should perform

troubleshooting or maintenance functions on the Drive. Failure

to comply may result in personal injury and/or equipment

damage.

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1-2 Understanding the Basic Principles

ESD Sensitivity Precaution

During Start-up the following information should have been recorded for

reference during troubleshooting. If it was not, record the following at this

time:

• An accurate list of Drive Setup and Conﬁguration parameters, in case the

EEPROM is corrupted. Tables are supplied in Chapter 6 for this purpose.

• Software Version numbers should be recorded for each board. These are

necessary to provide to on-site personnel or when calling for assistance.

• Drive and motor nameplate data should have been recorded at start-up

and maintained for ready reference during troubleshooting. Many

systems do not allow for easy access to the motor after startup. If the

motor nameplate data was not recorded previously, attempt to do so at

this time.

ATTENTION: This Drive may contain ESD (Electrostatic

Discharge) sensitive parts and assemblies. Static control

precautions are required when installing, testing, servicing or

repairing this assembly. Component damage may result if ESD

control procedures are not followed. If you are not familiar with

static control procedures, reference U.S. Department of Defense,

DOD-HDBK-263, Electrostatic Discharge Control Handbook for

protection of Electronic Parts, Assemblies and Equipment or any

other applicable ESD Protection Handbook.

ATTENTION: When replacing boards containing ﬁrmware

EPROM modules, Do Not transfer EPROMs from the damaged

board to the replacement board. Electrostatic Discharge (ESD),

Electromagnetic Interference (EMI), excessive heat,

contamination of printed circuit boards (PCB), and connections

that are damaged or improperly seated, etc., can cause serious

malfunctions to occur in the 1395 drive. An attempt should be

made to correct any of these environmental conditions prior to

installing new components.

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Understanding the Basic Principles 1-3

Safety Facts to Read Before

Proceeding

ATTENTION: Severe injury or death can result from electrical

shock, burn, or unintended actuation of controlled equipment.

Hazardous voltages may exist in the cabinet even with the circuit

breaker in the off position. Recommended practice is to

disconnect and lock out control equipment from power sources,

and discharge stored energy in capacitors, if present. If it is

necessary to work in the vicinity of energized equipment, the

safety related work practices of NFPA 70E, Electrical Safety

Requirements for Employee Workplaces, must be followed. DO

NOT work alone on energized equipment.

ATTENTION: Potentially fatal voltages may result from

improper usage of oscilloscope and other test equipment. The

oscilloscope chassis may be at a potentially fatal voltage if not

properly grounded. If an oscilloscope is used to measure high

voltage waveforms, use only a dual channel oscilloscope in the

differential mode with X 100 probes. It is recommended that the

oscilloscope be used in the A minus B Quasi-differential mode

with the oscilloscope chassis correctly grounded to an earth

ground. Refer to equipment safety instructions for all test

equipment before using with the 1395.

ATTENTION: The CMOS devices used on the control circuit

boards can be destroyed or damaged by static charges. If

personnel will be working near static sensitive devices, they must

be appropriately grounded. If you are not familiar with static

control procedures, reference A-B publication 8000-4.5.2

Guarding Against Electrostatic Damage or any other applicable

ESD Protection Handbook.

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1-4 Understanding the Basic Principles

Notes:

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Chapter 2

Malfunctions with Indications

General

Most malfunctions that occur induce a fault response from the 1395 drive.

This aids greatly in determining what malfunction has occurred. By

recording all of the faults indicated by the 1395 and using the

accompanying information, most problems can be corrected. The 1395

employs extensive diagnostics which monitor both internal and external

operating conditions and responds to incorrect conditions as programmed

by the user.

Hard Faults

A Hard Fault is the highest priority fault which indicates a condition in

which the 1395 has detected an internal malfunction and has determined

that operation can no longer continue. This type of fault indicates that a

major internal component or system has malfunctioned and that control of

the drive functions may be lost. The response of the drive to a Hard Fault is

a coast stop or whenever possible, a controlled motor stop.

A rotating motor will stop according to the Torque Mode commanded. The

following is an example of the action that will occur based on the value of

Parameter 625 “Torque Mode”

1. If Parameter 625 = 0 (Zero Torque) the drive will immediately phase

back the armature bridge and open the DC contactor.

2. If Parameter 625 = 1 (Velocity Regulate) the Drive will ramp the motor

velocity to zero and then open the contactor.

3. If Parameter 625 = 2 (External Torque Regulate) the Drive will

immediately phase back the armature bridge and open the DC contactor.

4. If Parameter 625 = 3 (Min Select) the Drive will immediately phase back

the armature bridge and open the DC contactor.

5. If Parameter 625 = 4 (Max Select) the Drive will immediately phase

back the armature bridge and open the DC contactor.

6. If Parameter 625 = 5 (Load Response) the Drive will immediately phase

back the armature bridge and open the DC contactor.

When a Hard Fault has occurred, fault recovery can only be accomplished

by initiating a system RESET or cycling AC line power. Examples of Hard

Faults include:

Handshake Fault - A fault between processors that indicate communication

or functionality was lost by one, or both processors.

Internal Memory Fault - A fault detected by a processor that indicates a

component malfunction.

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2-2 Malfunctions with Indications

Soft Faults

A Soft Fault indicates a condition in which the 1395 has detected a

malfunction that could cause damage to the drive control, power

components, or the motor. It may also indicate that undesirable operating

conditions exist external to the drive. This type of fault is used to protect the

drive system components from damage due to both internal and external

malfunctions. It differs from the Hard Fault in that the 1395 can, in most

cases, maintain proper control during the fault.

A Soft Fault is a second priority fault. When it occurs the response of the

drive is to initiate a coast stop or controlled motor stop. Fault recovery is

accomplished by a Clear Fault command, a system RESET command, or by

cycling AC line power.

Examples of Soft Faults are:

Velocity Feedback Loss - Fault detected when the selected feedback device

malfunctions. The drive will respond with a coast stop.

SCR Overtemperature Trip - detected when the thermal switch opens on the

power structure heat sink. The drive will respond by initiating a controlled

motor stop.

Warning Faults

A Warning Fault is the lowest priority fault which indicates a condition that

if left uncorrected, could result in a Soft Fault. This type of fault is designed

to annunciate a condition present in the system. When a Warning Fault

occurs, the appropriate Fault Code is entered into the Fault Queue and the

Fault Status parameters reﬂect the condition present. The drive will not

command a stop, and operation will continue unaffected. Fault Recovery is

accomplished by initiating a Clear Fault command, but is not necessary for

continued operation. Examples of Warning Faults are:

Motor Overload Pending - Detected when the armature current exceeds

115% (default value of parameter 720) of the motor armature current rating.

The drive will respond by indicating a Warning Fault and entering a

message into the Fault Queue, if parameter 632, bit 0 is set to zero.

Bridge Overload Pending - Detected when the armature current exceeds

105% of the bridge rating. The drive will respond by indicating a Warning

Fault, and entering a message into the Fault Queue, if parameter 632, bit 2 is

set to zero.

Fault Response Selection

A number of fault conditions in the 1395 may be conﬁgured to respond as

either Soft or Warning type faults. This allows the user to control the

response of the drive to some fault conditions based on his unique

application requirements. Parameter 623 “Fault Select” is a bit coded word

which controls whether eight predetermined faults will cause a Soft or

Warning type response. Bit deﬁnitions for parameter 623, corresponding to

the eight faults, are given in

Table 2.A. A fault condition will cause a Soft

Fault at this time.

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Malfunctions with Indications 2-3

A Soft Fault response will occur if the corresponding bit is set to 1. A

Warning response will occur if the corresponding bit is set to 0.

The default for all bits of parameter 623, when the parameter table is

initialized, is 1. This causes all of the faults listed in

Table 2.A to respond as

a Soft Fault type. For a fault to respond as a Warning Fault, the

corresponding bit must be set to 0 by the user. If the faults above are

conﬁgured as Warning Faults, then a provision should be made to report

these warnings through the PLC or other external device.

Conﬁguring “Waiting Safe Arm Volts” (bit 5=0) and “Waiting Zero Arm

Current” (bit 6=0) as Warning faults is recommended. This allows the

current loop to attempt to correct the condition without causing nuisance

trips. Drive operation is continued even when these faults are conﬁgured as

Warning Faults. ALL other bits should be set to 1 in most applications.

Three warning faults can be disabled by bit manipulation of parameter 632:

If a bit is set to 1, that particular fault will not be reported in the fault

word (parameter 100).

Table 2.A Fault Select Parameter 623

Parameter 632 Associated Fault

Bit 0 = Motor Overload Pending VP-16, (reference parameter 720)

Bit 1 = Excessive armature volts demand VP-36

Bit 2 = Bridge Overload Pending VP-39 (reference parameter 615)

Bit

Fault

Number Fault Deﬁnition Fault Description

0 VP-14 SCR Overtemp Occurs when the SCR heat sink (HST) thermo switch reaches 85 degrees C (185

degrees F) for 1 second. If bit 0 = 1, then a fault occurrence will cause a controlled

motor stop.

1 VP-15 Motor Overtemp Occurs when the external overtemp discrete input is low for speciﬁed delay of

Param 725. If bit 1 = 1, then a fault occurrence will cause a controlled motor stop.

2 VP-17 Overload Tripped Occurs when the armature current output has exceeded the selected motor

overload coefﬁcients. These coefﬁcients are selected in parameter 629 “Mtr

Overload Sel”. If bit 2 = 1, then a fault occurrence will cause a controlled motor stop.

3 VP-18 Stall Occurs when the armature current output is at current limit and velocity is within the

zero speed tolerance (parameter 710) for the time speciﬁed in parameter 727 “Stall

Delay”. If Bit 3 = 1, then a fault occurrence will cause a Coast Stop.

4 VP-20 AC Voltage Occurs when the incoming AC line voltage exceeds +15% or–20% of voltage

speciﬁed in parameter 617 “Rated AC Line” for 1 second. If Bit 4 = 1 then a fault

occurrence will cause a controlled motor stop.

5 VP-34 Waiting Safe

Arm Voltage

Occurs when armature CEMF is too high to allow successful commutation during a

forward to reverse bridge change. If bit 5 =1, then a fault occurrence will cause a

Coast Stop. If bit 5 = 0, then an occurrence will cause the motoring bridge to be

held off, allowing the motor to coast to a lower CEMF. When an acceptable level is

reached the drive will allow a bridge change and operation will continue.

6 VP-35 Waiting Zero

Arm Current

Occurs when the armature current does not go to zero when a bridge change is

commanded. If bit 6 = 1, then a fault occurrence will cause a Coast Stop. If bit 6 = 0,

then an occurrence will cause the drive to attempt to force the current to zero.

7 VP-31 Arm Bridge

Overload Trip

Occurs when armature current output exceeds the predetermined armature bridge

overload coefﬁcients which are based on 150% for 60 seconds, 200% for 10

seconds, 260% for 5 seconds. If bit 7 = 1, then a fault occurrence will cause a Coast

Stop.

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2-4 Malfunctions with Indications

Fault Setup Parameters

Certain Faults have setup parameters associated with them. They allow the

user to set thresholds and time delays according to the particular

application. A description of faults with setup parameters follows:

No. Name Description Associated Parameter(s)

VP-10 Feedback

Loss

This Soft fault occurs when the

measured velocity feedback from

the selected feedback device is less

than parameter 732 “Tach Loss Vel”

and the CEMF of the motor is

greater than parameter 731 “Tach

Loss CEMF”.

Velocity Fdbk (106) < Tach Loss Vel

(732), AND calculated CEMF from

Arm Voltage Fdbk (105) > Tach Loss

CEMF (731), THEN Fault on

Feedback Loss.

Parameter 731 “Tach Loss CEMF”. This

parameter indicates the lower limit of CEMF of

the motor voltage allowed for determination of

feedback loss. Programmable range is 0-33%.

Parameter 732 “Tach Loss VEL” This parameter

indicates the upper limit of velocity feedback

measured by the selected feedback device

allowed for determination of feedback loss.

Programmable range is 0.244, ±10%.

Parameter 731 “Tach Loss CEMF” must always

be programmed to a value greater than

parameter 732 “Tach Loss VEL” or nuisance trips

will occur.

VP-12 Absolute

Overspeed

This Soft fault occurs when motor

velocity exceeds the maximum

forward/reverse speed limits by the

absolute overspeed level.

Parameter 724 “ABS Overspeed” This

parameter indicates the incremental motor

velocity (RPM) above parameter 607 “Rev

Speed Limit” or parameter 608 “Fwd Speed

Limit” that must be detected in parameter 106

“Velocity Fdbk” to cause the above fault.

Programmable range is zero to Base Speed.

See also parameters 607 “Rev Speed Limit” and

608” Fwd Speed Limit”.

VP-13 Motor Field

Loss

This Soft fault occurs when the ﬁeld

current feedback is less than 50% of

ﬁeld current reference for the time

delay speciﬁed.

Parameter 730 “Fld Failure Dly” This parameter

indicates the time the ﬁeld current feedback

must remain less than 50% of the ﬁeld current

reference before the above fault is indicated.

Programmable range is 0-5 seconds.

Parameter 627 “Flux Mode Select”. Bit 6 can be

used to disable ﬁeld loss detection. For normal

operation, set it to 0 to detect ﬁeld loss

conditions.

VP-14 SCR

Overtemp

This fault occurs when the SCR heat

sink (HST) thermoswitch and/or

vane switch (MKVA) opens after the

speciﬁed time delay.

Parameter 726 “SCR Overtemp Dly”. This

parameter indicates the time the thermoswitch

must remain open before the above fault is

indicated. Programmable range: 0-3276.7 secs.

VP-15 External

Overtemp

This selectable fault occurs when

the external overtemp discrete input

(TB3-1& 2) is low for the time delay

speciﬁed.

Parameter 725 “Motor Ovtemp Dly”. This

parameter indicates the time the discrete input

must remain low before the above fault is

indicated. Programmable range: 0-3276.7 secs.

Verify that the motor thermostat is properly

wired. If the motor is not equipped with a

thermostat, 115 VAC or 24V DC must still be

applied to TB3 terminal 2. See 1395 Installation

Manual (publication 1395-5.40).

ATTENTION: Uncontrolled motor rotation can cause injury or equipment damage i

ﬁeld loss detection is disabled. Field loss protection can only be disabled if using a

external ﬁeld supply. Set bit 6 to disable ﬁeld loss detection.

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Malfunctions with Indications 2-5

Fault Status Indicators

The Bulletin 1395 contains various Fault Status Indicators which can be

used to monitor the faults that occur in the drive. These are available for use

with the Bulletin 1300 Programming Terminal (DHT/DMT), the PLC/Node

adapter, the PLC/Data Highway +, the Multi Communication Adapter and

through the use of discrete I/O devices.

VP-16 Thermal

Overload

Pending

This Warning fault occurs when the

armature current exceeds the Motor

Overload Pending Level.

Parameter 720 “Ovrld Pend Level”. It is used to

indicate that the present armature current output

exceeds a predetermined level and continued

operation at this level may cause damage to the

motor and/or process. This warning fault can be

disabled. Refer to Parameter 632.

VP-17 Thermal

Overload

Tripped

This selectable fault occurs when

armature current output over time

has exceeded the selected motor

overload coefﬁcients.

Parameter 629 “Mtr Overload Sel”. This

parameter is used to select the coefﬁcients for

the motor thermal overload function.

0. Overload function disabled

1. 60 seconds to trip at 150% armature current

for externally cooled motors.

2. 60 seconds to trip at 200% armature current

for externally cooled motors.

3. 60 seconds to trip at 150% armature current

for self cooled motors.

4. 60 seconds to trip at 200% armature current

for self cooled motors.

VP-18 Motor

Stalled

This selectable fault occurs when

the armature output is at current

limit and velocity is within the zero

speed tolerance for the time delay

speciﬁed.

Parameter 727 “Stall Delay”. This parameter

indicates the time that the armature current must

remain at current limit with the motor velocity

within the zero speed tolerance before the above

fault is indicated. Programmable range: 0-100

seconds.

See also parameters 663 “Fwd Brdg Cur Lim”,

664 “Rev Brdg Cur Lim”, and 710 “Zero Speed

Tol”.

VP-20 AC Voltage This selectable fault occurs when

the incoming AC line voltage

exceeds +15% or –20% of rated AC

line voltage for the time delay

speciﬁed.

Parameter 617 “Rated AC Line”. This parameter

indicates the incoming AC line voltage and is

used as a basis for the above comparison and

resulting fault. Programmable range: 150-460V.

Parameter 728 “AC Line Tol Dly”. This parameter

indicates the time the AC Line must remain out

of tolerance before the above fault is indicated.

Programmable range: 0-1.0 secs.

No. Name Description Associated Parameter(s)

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2-6 Malfunctions with Indications

Fault Status Indicators

Parameter Name Description

100 Logic

Status

Parameter 100 uses bits 0 and 1 to indicate the highest priority fault level

present in the drive. The two bits are binary coded to allow for four

different indications. This source conﬁguration parameter can be linked to

various adapters depending on the application. It can also be monitored

by the Programming Terminal.

101 Drive

Fault

Parameter 101 is a bit coded source conﬁguration parameter that can

report the status of Soft and Warning Faults that exist in either the Current

Processor or Velocity Processor. The selection between Current

Processor or Velocity Processor faults is made in the setup parameter 630

“Fault Report”.

630 Fault

Report

Parameter 630 is a setup parameter which determines whether the

Current or Velocity Processor faults will be reported. If parameter 630 = 0,

then Current Processor faults will be reported in parameter 101. If

parameter 630 = 1, then Velocity Processor faults will be reported in

parameter 101. The corresponding bit deﬁnitions can be found below.

Bit 1 Bit 0 Deﬁnition

0 0 No Fault

0 1 Warning Fault

1 0 Soft Fault

1 1 Hard Fault

Bit Fault Deﬁnition(630=0) Fault Deﬁnition(630=1)

0 CP-06 Phase Loss VP-10 Feedback Loss

1 CP-05 Logic Power Supply ECOAST Status (0=Closed,

1=Open)

(1)

Bit 1 ECOAST Status is not a fault indicator but does allow the operator to

monitor, through a source conﬁguration parameter, whether the ECOAST circuit

is closed. The ECOAST string allows the drive to close the DC contactor. If the

string is closed bit 1 will be set to 0 and the DC contactor will be allowed to close

if commanded. If the circuit is open then bit 1 will be set to 1 and the DC

contactor will be held open.

2 CP-08 AC Overcurrent Trip VP-12 Absolute Overspeed

3 CP-09 DC Fault (Overcurrent) VP-13 Motor Field Tolerance

4 CP-07 Overcurrent Trip (AC/DC) VP-14 SCR Overtemp

5 VP-31 Arm Bridge Overload Trip VP-15 External Overtemp

6 VP-32 Motor Field Loss VP-16 Thermal Overload Pending

7 Deﬁned for internal use only VP-17 Thermal Overload Tripped

8 VP-34 Waiting Safe Arm Voltage VP-18 Motor Stalled

9 VP-35 Waiting Zero Arm Current VP-19 Contactor Failure

10 Excessive Arm Voltage Demand VP-20 AC Voltage

11 Deﬁned for internal use only VP-21 VP Handshake with SP

12 Deﬁned for internal use only VP-22 VP Handshake with CP

13 VP-39 Arm Bridge Overload Pend VP-23 SP Mode Request Not

Honored

14 Not Used VP-24 CP Not in VP Requested Mode

(2)

Status of Param 630 “Fault Report” Status of Parameter 630 “Fault

Report”

(2)

Bit 15 in either selection reﬂects the present status of parameter 630

“FaultReport”. If bit 15 is 0 then the Current Processor Fault status is being

reﬂected in parameter 101. If bit 15 is 1 then the Velocity Processor Fault Status

is bein

reﬂected.

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Malfunctions with Indications 2-7

Bulletin 1300 Programming

Terminal

You can also use the Bulletin 1300 Programming Terminals to monitor the

terminal fault status of the 1395 drive. Any of the fault status parameters

(100, 101, 630) can be monitored through the Programming Terminal. Use

Main Menu item 3 “Parameter”.

In addition, when a Hard or Soft Fault occurs, the fault message will appear

immediately on the screen of the programming terminal. To view all of the

faults in the Fault Queue, select Main Menu item 7 “Faults”. Then select

Fault Menu Item 1 “View Faults” to view the last 16 faults that occurred.

Use the INC/DEC keys to move through the Fault Queue for that processor.

Use the ENTER key to view other processor’s fault queues if they exist. All

types of detectable faults that have occurred will be present in the Fault

Queue.

Any problems with the Programming Terminal itself will be evidenced by a

missing or non-active Pendulum on the initial display. If programming

terminal problems are suspected, refer to the terminal instruction manual.

Fault Descriptions and

Recovery

Each processor in the 1395 drive has unique fault detection and message

capabilities which it can generate. These fault diagnostics can consist of

Hard, Soft, or Warning type faults and can cause the drive to respond in

various ways. The faults detected by each processor are listed, along with a

complete description, possible causes and possible fault recovery

procedures that will allow the malfunction to be corrected.

A recurring fault, as referenced below in the Recovery procedure, refers to a

fault that repeats as soon as normal operation is attempted. Faults that

reoccur at random intervals may be due to a transient condition and not

necessarily a board or component malfunction.

Fault Display on HHT or DHT

System Processor Faults

(SP–XX)

In general most System Processor faults indicate that an internal processor

error somewhere in the 1395 system has occurred. These faults can be

induced by Electrostatic Discharge (ESD), Electro Magnetic Interference

(EMI), excessive heat, contamination of printed circuit boards (PCB),

connections that are damaged or do not seat properly, etc. An attempt

should be made to correct any of these environmental conditions prior to

replacing components in the drive. This should reduce the possibility of

reoccurrence. If board replacement is necessary, replace the complete

board, DO NOT reuse EPROM chips.

No. Name Description Recovery

10 Comm Fault Attempting to

re-establish

communication.

1. Drive may be held in a continual reset. If

Reset/Stop input TB3-3, is held high (24 or

115 volts applied). and parameter 620 = 0

(Default setting), Drive will be in a continual

reset. Set parameter 620 to a non zero value.

2. Check integrity of PE and TE ground. Check

for “Floating” TE, or ground loops

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2-8 Malfunctions with Indications

System Processor Faults

No. Name Description Recovery

SP-00 Ill Fault (Warning) Internal processor error was detected and

corrected. Operation is unaffected.

No action is required.

SP-01 Proc OK

SP-10 Queue Bad Dest

(Warning)

Internal processor error was detected and

corrected. An unsolicited reply (possibly

due to noise) from a non-existing device

could cause this warning fault. Operation is

unaffected. Could also be caused by

incorrect block transfer data or byte length.

No action is required or correct block

transfer data.

SP-11 Queue Bad Tag

(Warning

Internal processor error was detected and

corrected. Operation is unaffected.

No action is required.

SP-14 Queue RX Msg

Index (Warning)

Internal processor error was detected and

corrected. Operation is unaffected.

No action is required.

SP-15 Queue TX Msg

Index (Warning)

Internal processor error was detected and

corrected. Operation is unaffected.

No action is required.

SP-16 VP Write Fault

(Warning)

Internal processor error was detected and

corrected. Operation is unaffected.

No action is required.

SP-17 CP Write Fault

(Warning)

Internal processor error was detected and

corrected. Operation is unaffected.

No action is required.

SP-18 PB Write Fault

(Warning)

Internal processor error was detected and

corrected. Operation is unaffected.

No action is required.

SP-19 PA Write Fault

(Warning)

Internal processor error was detected and

corrected. Operation is unaffected.

No action is required.

SP-20 VP Read Fault

(Warning)

Internal processor error was detected and

corrected. Operation is unaffected.

No action is required.

SP-21 CP Read Fault

(Warning)

Internal processor error was detected and

corrected. Operation is unaffected.

No action is required.

SP-22 PB Read Fault

(Warning)

Internal processor error was detected and

corrected. Operation is unaffected.

No action is required.

SP-23 PA Read Fault

(Warning)

Internal processor error was detected and

corrected. Operation is unaffected.

No action is required.

SP-24 Recv Timeout

(Warning)

Internal processor error was detected and

corrected. Operation is unaffected.

No action is required.

SP-25 Bad Channel

Value (Soft)

Internal processor error detected. A

controlled motor stop will be initiated.

Execute a Clear Fault and continue

operation. If the fault reoccurs, replace

Main Control Board.

SP-30 EEPROM None or

Empty (Soft)

Either the EEPROM is not installed or it

has not been initialized. This fault may also

occur if the data in the EEPROM has been

corrupted. All Setup and Conﬁguration

data does not exist and the Drive Start-up

Procedure must be repeated.

Check that the EEPROM is installed in

UMC8 on the Main Control Board.

Execute an “initialize” and repeat the

Drive Start-up Procedure. Clear faults

before attempting to operate the drive.

SP-32 EEPROM Verify

(Soft)

A data write to the EEPROM cannot be

accomplished. This indicates that the

EEPROM component has malfunctioned.

Check J14 Jumper on Main Control

Board for Write Protect Position. If the

fault reoccurs Replace the Main Control

Board and repeat the Drive Start-up

Procedure before attempting to operate

the drive.

SP-35 Handshake VP

(Hard)

Internal communication between

processors has malfunctioned. A

controlled motor stop will be initiated.

Verify DMT has ﬁlter installed. Execute

System RESET or cycle power and

attempt normal operation. If the fault

reoccurs, check integrity of TE and PE

grounding before replacing Main Control

Board.

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Malfunctions with Indications 2-9

SP-38 Handshake PB

(Hard)

Internal communication between the

System Processor and the Port B Adapter

Board has Malfunctioned. A controlled

motor stop will be initiated.

Execute System RESET or cycle power

and attempt normal operation. Check the

ribbon connector that plugs into J6 on the

Main Control Board and the Adapter

Board, replace if damage is suspected. If

the malfunction reoccurs, replace the

Adapter Board. If the malfunction still

reoccurs check integrity of TE and PE

grounding before replacing the Main

Control Board.

SP-39 Handshake PA

(Hard)

Internal communication between the

System Processor and the Port A Adapter

Board has malfunctioned. A controlled

motor stop will be initiated.

Execute System RESET or cycle power

and attempt normal operation. Check the

ribbon connector that plugs into J7 on the

Main Control Board and the Adapter

Board, replace if suspect. If the fault

reoccurs, replace the Adapter Board. If

the fault still reoccurs, check integrity of

TE and PE grounding before replacing

the Main Control Board.

SP-43 Port Conﬁgd-No

Adapter (Soft)

The System Processor has detected that

an Adapter Board, which has conﬁguration

parameters linked to it, is not installed.

This could result in undesirable operation.

This fault may also occur when trying to

link conﬁguration parameters to

non-existing adapters.

The missing Adapter Board should be

replaced or the conﬁguration parameters

linked to the missing adapter should be

removed. A System RESET can then be

executed and operation continued.

SP-50 Mode VP/CP

Timeout (Hard)

Internal communication between

processors has malfunctioned. A

controlled motor stop will be initiated.

Execute System RESET or cycle power

and attempt normal operation. If the fault

reoccurs, replace Main Control Board.

SP-51 Mode PB Timeout

(Hard)

Internal communication between the

System Processor and the Port B Adapter

has malfunctioned. A controlled motor stop

will be initiated.

Execute System RESET or cycle power

and attempt normal operation. If the fault

reoccurs, replace the Port B Adapter. If

the fault reoccurs, replace the Main

Control Board.

SP-52 Mode PA Timeout

(Hard)

Internal communication between the

System Processor and the Port A Adapter

has malfunctioned. A controlled motor stop

will be initiated.

Execute System RESET or cycle power

and attempt normal operation. If the fault

reoccurs, replace the Port A Adapter. If

the fault persists, replace the Main

Control Board.

SP-53 Processor VP

Faulted (Hard)

The Velocity Processor has been detected

as being in a faulted state. A controlled

motor stop will be initiated.

Check the Fault Queue to see if the

Velocity Processor fault may have been

recorded. These faults must be corrected

before further operation. Execute System

RESET or cycle power and attempt

normal operation. If the fault reoccurs,

replace the Main Control Board.

System Processor Faults

No. Name Description Recovery

ATTENTION: Do Not execute a Clear Fault without correcting the cause of the

fault. This will allow the drive to operate and may cause undesirable operation. Th

hazard of personal injury or equipment damage exists if faults are not corrected.

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2-10 Malfunctions with Indications

SP-54 Processor PB

Faulted (Soft)

The Port B Adapter has been detected as

being in a faulted state. A controlled motor

stop will be initiated.

Check the Fault Queue to see if the

Adapter fault may have been recorded.

These faults must be corrected before

further operation. Execute a Clear Fault

and attempt normal operation. If the fault

reoccurs, replace the Port B Adapter. If

the fault reoccurs, replace the Main

Control Board.

SP-55 Processor PA

Faulted (Soft)

The Port A Adapter has been detected as

being in a faulted state. A controlled motor

stop will be initiated.

Check the Fault Queue to see if the

Adapter fault may have been recorded.

These faults should be corrected before

further operation. Execute System

RESET or cycle power and attempt

normal operation. If the fault reoccurs,

replace the Port A Adapter. If the fault

occurs again, replace the Main Control

Board.

SP-56 Illegal Mode

Request (Soft)

Internal processor communication error

detected. A controlled motor stop will be

initiated.

Execute a Clear Fault and continue

operation. If the fault reoccurs, replace

Main Control Board.

SP-57 Loc Mode Serial

Timeout (Soft)

This occurs when the Bulletin 1300

Programming Terminal is in LOCAL

CONTROL and serial communication is

interrupted. A controlled motor stop will be

initiated. This fault most often occurs when

the programming terminal has LOCAL

CONTROL and the serial cable to the drive

is unplugged or damaged.

Check the programming terminal

connection to the drive. The connector is

located next to the TB3 terminal strip on

the 1396. Also check the connection on

the programming terminal back if it is a

Door Mounted Terminal (DMT). Execute

a Clear Fault and continue operation. If

the fault reoccurs, replace the

Programming Terminal and/or cable. If

the fault reoccurs again, replace the

cable assembly from the Main Control

Board’s J4 to the D-Shell connector next

to TB3. If the fault is still persistent,

replace the Main Control Board.

SP-58 Task Timeout

(Hard)

Internal processor error detected. A

controlled motor stop will be initiated.

Execute System RESET or cycle power

and attempt normal operation. If the fault

reoccurs, replace Main Control Board.

SP-60 Processor VP

Hard (Hard)

The Velocity Processor has been detected

as being in a Hard Fault state and is

non-operational. A coast stop will be

initiated. This fault usually occurs when the

Velocity Processor has malfunctioned

during power-on diagnostics or has

experienced a major interruption of

operation.

Check the Fault Queue to see if the

Velocity Processor fault may have been

recorded. These faults must be corrected

before further operation. Execute System

RESET or cycle power and attempt

normal operation. Check TE & PE

grounding, if the fault continues to

reoccur, replace the Main Control Board.

SP-61 Processor CP

Hard (Hard)

The Current Processor has been detected

as being in a Hard Fault state and is

non-operational. A coast stop will be

initiated. This fault usually occurs when the

Current Processor has malfunctioned

during power-on diagnostics or has

experienced a major interruption of

operation.

Check the Fault Queue to see if the

Current Processor fault may have been

recorded. These faults must be corrected

before further operation. Execute System

RESET or cycle power and attempt

normal operation. Check TE & PE

grounding, if the fault continues to

reoccur, replace the Main Control Board.

System Processor Faults

No. Name Description Recovery

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Malfunctions with Indications 2-11

SP-62 Processor PB

Hard (Hard)

The Port B Adapter Processor has been

detected as being in a Hard Fault state and

is non-operational. A controlled motor stop

will be initiated. This fault usually occurs

when the Adapter’s processor has failed

power-on diagnostics or has experienced a

major interruption of operation.

Check the Fault Queue to see if the

Adapter’s processor fault may have been

recorded. These faults should be

corrected before further operation.

Execute System RESET or cycle power

and attempt normal operation. If the fault

reoccurs, replace the Port B Adapter.

Check TE & PE grounding, if the fault

continues to reoccur, replace the Main

Control Board.

SP-63 Processor PA

Hard (Hard)

The Port A Adapter Processor has been

detected as being in a Hard Fault state and

is non-operational. A controlled motor stop

will be initiated. This fault usually occurs

when the Adapter’s processor has

malfunctioned during power-on diagnostics

or has experienced a major interruption of

operation.

Check the Fault Queue to see if the

Adapter’s processor fault may have been

recorded. These faults must be corrected

before further operation. Execute System

RESET or cycle power and attempt

normal operation. If the fault reoccurs,

replace the Port A Adapter. Check

grounding, if the fault occurs again,

replace the Main Control Board.

SP-64 VP/CP Flt Mode,

No Status (Soft)

Internal processor communication error

detected. A controlled motor stop will be

initiated.

Execute a Clear Fault and continue

operation. If the fault reoccurs, replace

Main Control Board.

SP-65 PB Flt Mode, No

Status (Soft)

Internal communication between the

System Processor and the Port B Adapter

has malfunctioned. A controlled motor stop

will be initiated.

Execute a Clear Fault and attempt

normal operation. If the fault reoccurs,

replace the Port B Adapter. If the fault

occurs again, replace the Main Control

Board.

SP-66 PA Flt Mode, No

Status (Soft)

Internal communication between the

System Processor and the Port A Adapter

has malfunctioned. A controlled motor stop

will be initiated.

Execute a Clear Fault and attempt normal

operation. If the fault reoccurs, replace

the Port A Adapter. If the fault occurs

again, replace the Main Control Board.

SP-83 Diag EEPROM

(Soft)

The EEPROM checksum calculated during

power-on diagnostics is incorrect. This

usually indicates that data contained in the

EEPROM has been corrupted.

Execute a Clear Fault. Re-initialize

EEPROM again, re-load program and

clear fault If the fault reoccurs often, then

replace the Main Control Board.

SP-85 Diag VP Mbus

(Hard)

Internal processor error occurred during

power-up diagnostics.

Execute System RESET or cycle power

and attempt normal operation. Check

grounding, if the fault reoccurs, replace

Main Control Board.

SP-86 Diag Adapter B

Mbus (Hard)

An internal communication error between

the System Processor and the Port B

Adapter board has occurred during

power-on.

Execute System RESET or cycle power

and attempt normal operation. Check the

ribbon connector that plugs into J6 on the

Main Control Board and the Adapter

Board, replace if damage is suspected. If

the fault reoccurs check grounding ﬁrst,

then replace the Adapter Board. If the

fault persists, replace the Main Control

Board.

System Processor Faults

No. Name Description Recovery

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2-12 Malfunctions with Indications

Velocity Processor (VP–XX)

The Velocity Processor is responsible for fault monitoring of control

variables throughout the drive. This includes monitoring velocity control,

armature and ﬁeld outputs to the motor, incoming line conditions, and

communications to the System Processor and Current Processor. These

faults can be induced by problems external to the immediate drive such as a

malfunction of a feedback device, excessive load on the motor, incoming

line variations, etc. An attempt to identify and correct these conditions, if

applicable, must be done prior to replacing components in the drive.

Internal processor faults that occur can be induced by Electrostatic

Discharge (ESD), Electro Magnetic Interference (EMI), excessive heat,

contamination of printed circuit boards (PCB), improper or damaged

connections, etc. An attempt must be made to correct any of these

environmental conditions prior to replacing components in the drive. This

can help reduce the possibility of reoccurrence.

Faults VP-10 through VP-24 are reported in parameter 101 “Drive Fault”

when parameter 630 “Fault Report” is set to a value of 1. The bit

assignments for parameter 101 are given in ( ) where applicable. See Fault

Type Selection.

SP-87 Diag Adapter A

Mbus (Hard)

An internal communication error between

the System Processor and the Port A

Adapter board has occurred during

power-on.

Execute System RESET or cycle power

and attempt normal operation. Check the

ribbon connector that plugs into J7 on the

Main Control Board and the Adapter

Board, replace if damage is suspected. If

the fault reoccurs check grounding ﬁrst,

then replace the Adapter Board. If the

fault still occurs, replace the Main Control

Board.

SP-90 Serial WDG

Warning

(Warning)

Internal processor error was detected and

corrected. Operation is unaffected.

No action is required.

SP-91 Serial WDG Soft

(Soft)

Internal processor error detected. A

controlled motor stop will be initiated.

Execute a Clear Fault and attempt

normal operation. If the fault reoccurs,

replace Main Control Board.

System Processor Faults

No. Name Description Recovery

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Allen-Bradley 1395 Troubleshooting Manual

Allen-Bradley 1395 Troubleshooting Manual

Allen-Bradley 1395 Troubleshooting Manual

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